Molding machine cylinder and its production method

ABSTRACT

A molding machine cylinder comprising a lining layer having a structure comprising 20-50% by area of tungsten carbide particles and 1-10% by area of tungsten-based metal carboboride particles in a nickel-based alloy matrix, and containing 1-7.5% by mass of Fe, can be produced by a centrifugal casting method comprising a first step of heating at higher than 1140° C. and lower than 1200° C., and a second step of heating at 1080-1140° C. after melting the raw material powder.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of International Application No.PCT/JP2015/055431 filed Feb. 25, 2015 (claiming priority based onJapanese Patent Application No. 2014-034238, filed Feb. 25, 2014), thecontents of which are incorporated herein by reference in theirentirety.

FIELD OF THE INVENTION

The present invention relates to a molding machine cylinder comprising alining layer having excellent wear resistance and corrosion resistance,and a method for producing such a molding machine cylinder by acentrifugal casting method at low cost.

BACKGROUND OF THE INVENTION

A molding machine cylinder used for injection-molding orextrusion-molding plastics, etc., is required to be resistant to wear byresins, additives, etc. during thermal molding, and be able to beproduced at relatively low cost. To meet such requests, abimetal-structure molding machine cylinder comprising a lining layerformed on an inner surface of a steel cylinder by a centrifugal castingmethod, the lining layer comprising tungsten carbide particles dispersedin a nickel alloy matrix, has conventionally been used.

To produce a molding machine cylinder having a lining layer, in whichhard particles such as tungsten carbide particles, etc. are dispersed ina nickel alloy matrix, by a centrifugal casting method, a mixed powderof nickel alloy powder and tungsten carbide powder is melted andcentrifugally cast in a cylinder, forming a centrifugally cast layercomprising an outer layer (lining layer), in which many hard particleshaving large specific gravities such as tungsten carbide particles, etc.are dispersed, and an inner layer containing less hard particles(particle-lack layer). Because the particle-lack layer should be removedto expose the lining layer, the particle-lack layer is preferably asthin as possible.

JP 2872571 B discloses a centrifugally cast composite tungsten carbidelining layer comprising 30-45% by weight of tungsten carbide, 35-50% byweight in total of nickel+cobalt, 1% or less by weight of molybdenum,10% or less by weight of chromium, 1-3% by weight of boron, 1-3% byweight of silicon, 2% or less by weight of manganese, 8-25% by weight ofiron, and 1% or less by weight of carbon. This lining layer hasexcellent wear resistance, because 25-45% by volume of tungsten carbideparticles having an average particle size of 6-12 μm are dispersed.However, JP 2872571 B does not describe how to stably control thethickness of a particle-lack layer at all. With the particle-lack layerhaving uneven thickness, not only the particle-lack layer but also partof the lining layer should be removed for safety margin, resulting in alow production yield. Also, the lining layer containing as much iron as8-25% by weight has poor corrosion resistance.

JP 4900806 B discloses a molding machine cylinder comprising a lininglayer of a wear-resistant, corrosion-resistant alloy, which is formed onan inner surface of a hollow steel cylinder, the lining layer comprisinga nickel-containing matrix, and hard particles comprising tungstencarbide dispersed in metal tungsten. JP 4900806 B describes that an arearatio of hard particles in the lining layer is 20-80%, and that thelining layer may further contain 5-20% by area of tungsten boride. JP4900806 B further describes that tungsten boride is centrifugallyseparated together with hard particles during centrifugal casting,resulting in proper distances between hard particles in the lininglayer. However, it is difficult to stably control the thickness of theparticle-lack layer in this cylinder, too. With the particle-lack layerhaving uneven thickness, the centrifugally cast layer should be cut deepto remove the unevenly thick particle-lack layer, resulting in a lowmaterial yield. In addition, special particles containing tungstencarbide dispersed in metal tungsten should be prepared as hardparticles, resulting in a high production cost.

JP 5095669 B discloses a lining material centrifugally cast in acylinder, which comprises 30-45% by mass in total of tungstenboride+tungsten carbide (tungsten boride/tungsten carbide=1 or less, andtungsten boride: 5-20% by mass), 35-50% by mass in total ofnickel+cobalt, 1% or less by mass of molybdenum, 10% or less by mass ofchromium, 1-3% by mass of boron, 1-3% by mass of silicon, 2% or less bymass of manganese, 5% or less by mass of iron, 1% or less by mass ofcarbon, and inevitable impurities. JP 5095669 B describes that with anadjusted mass ratio of tungsten carbide powder to tungsten boridepowder, the thickness of a particle-lack layer is controlled. However,tungsten boride powder added to the lining material in advance leads toa high material cost, and is dissolved in an alloy melt during castingbecause tungsten boride is poorer than tungsten carbide in thermalstability. In addition, tungsten boride particles having particle sizesof several micrometers or less, much smaller than the alloy powder in araw material, are not easily dispersed uniformly. Further, with toolarge a total amount of tungsten carbide powder and tungsten boridepowder, these powders have insufficient fluidity during centrifugalcasting, failing to achieve the uniform dispersion of tungsten carbideparticles and tungsten boride particles.

JP 2010-99693 A discloses a method for producing a wear-resistant lininglayer by (a) adding boride powder including WB or MoB to Co-based orN-based alloy powder containing B and Cr to prepare a mixed powder, (b)charging the mixed powder into a cylinder, (c) melting the mixed powderby heating it to a temperature of 1200° C. or higher while rotating thecylinder at 3 rpm, (d) forming a lining layer by centrifugal casting, inwhich the cylinder is rotated at a high speed of 2290-2300 rpm, and (e)finishing an inner surface of the lining layer by machining. However,because the mixed powder is melted at a high temperature of 1200° C. orhigher in this method, the inner surface of the cylinder is eroded, sothat a large amount of molten Fe enters the lining layer. Because thelining layer exhibits low corrosion resistance with a large Fe content,the erosion of the inner surface of the cylinder should be minimizedduring melting the mixed powder. Though boride powder is added in thismethod, tungsten boride is partially melted in the alloy melt because ofpoorer thermal stability than tungsten carbide, resulting ininsufficient improvement in wear resistance.

OBJECTS OF THE INVENTION

Accordingly, the first object of the present invention is to provide amolding machine cylinder comprising a centrifugally cast lining layerhaving excellent wear resistance and corrosion resistance.

The second object of the present invention is to provide a method forproducing a molding machine cylinder comprising a lining layer havingexcellent wear resistance and corrosion resistance, with a small cuttingdepth of a centrifugally cast layer by stably controlling the thicknessof a particle-lack layer, thereby forming the lining layer at low cost.

DISCLOSURE OF THE INVENTION

The molding machine cylinder of the present invention comprises a lininglayer formed on an inner surface of a steel cylinder by a centrifugalcasting method; the lining layer having a structure comprising 20-50% byarea of tungsten carbide and 1-10% by area of tungsten-based metalcarboboride particles in a nickel-based alloy matrix; and the lininglayer containing 1-7.5% by mass of Fe.

The metal carboboride particles preferably comprise 0.5-4% by mass of C,0.5-6% by mass of B, 65-85% by mass of W, and 1-20% by mass of Ni.

The metal carboboride particles preferably have an average particle sizeof 0.5-5 μm.

The tungsten carbide preferably has an average particle size of 1.5-15μm.

The lining layer preferably comprises 1.5-4% by mass of C, 0.5-3.5% bymass of B, 25-60% by mass of W, 1-10% by mass of Cr, 1-15% by mass ofCo, 0.1-3% by mass of Si, 0.1-2% by mass of Mn, and 0-5% by mass of Cu,the balance being nickel and inevitable impurities.

A matrix of the lining layer preferably comprises 0.05-1% by mass of C,0.5-3% by mass of B, 1-5% by mass of W, 2-20% by mass of Cr, 2-30% bymass of Co, 0.2-5% by mass of Si, 0.2-5% by mass of Mn, 2-15% by mass ofFe, and 0-10% by mass of Cu, the balance being nickel and inevitableimpurities.

The method of the present invention for producing a molding machinecylinder comprising a lining layer having a structure comprising 20-50%by area of tungsten carbide particles and 1-10% by area oftungsten-based metal carboboride particles in a nickel-based alloymatrix, and containing 1-7.5% by mass of Fe, comprises the steps of

charging a raw material for the lining layer comprising 40-70 parts bymass of nickel-based alloy powder containing 1-5% by mass of B, and60-30 parts by mass of tungsten carbide powder, into a steel cylinder;

melting the raw material for the lining layer while rotating thecylinder at 5-30 rpm;

increasing the number of rotation of the cylinder for centrifugalcasting, to form a centrifugally cast layer comprising an outside lininglayer and an inside particle-lack layer, on an inner surface of thecylinder; and

removing the particle-lack layer by machining;

the raw material for the lining layer being melted by a first step ofheating at higher than 1140° C. and lower than 1200° C., and a secondstep of heating at 1080-1140° C. after the first heating step.

The alloy powder preferably comprises 0.01-1% by mass of C, 1-5% by massof B, 2-20% by mass of Cr, 0.2-5% by mass of Si, 0.2-5% by mass of Mn,22-30% by mass of Co, 0-5% by mass of Cu, and 0-1% by mass of Fe, thebalance being nickel and inevitable impurities.

The alloy powder preferably has an average particle size of 20-300 μm.

The tungsten carbide powder preferably has an average particle size of1.5-15 μm.

EFFECTS OF THE INVENTION

Because a raw material for a lining layer is melted by the first step ofheating at higher than 1140° C. and lower than 1200° C., and the secondstep of heating at 1080-1140° C. in the present invention, the thicknessof a particle-lack layer can be stably controlled without addingtungsten boride powder to the raw material powder. Accordingly, thecutting depth of a centrifugally cast layer to expose the lining layercompletely can be reduced, lowering the production cost of the moldingmachine cylinder.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional view showing the molding machinecylinder of the present invention.

FIG. 2 is a scanning electron photomicrograph showing the centrifugallycast layer of Example 1.

FIG. 3 is a photograph showing the lining layer of Example 1, which ismapping-analyzed by EPMA to identify a matrix, tungsten carbideparticles and metal carboboride particles.

FIG. 4 is a schematic view showing an abrasive wear test.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The embodiments of the present invention will be explained in detailbelow without intention of restricting the present invention thereto.Proper modifications and improvements may be added based on the commonknowledge of those skilled in the art, within a range not deviating fromthe technical idea of the present invention.

As shown in FIG. 1, a melt of a raw material for a lining layercomprising nickel-based alloy powder containing B and tungsten carbidepowder is centrifugally cast onto an inner surface of a steel cylinder2, to form a centrifugally-cast hollow layer 3 on the inner surface ofthe steel cylinder 2. The centrifugally cast layer 3 comprises anoutside lining layer 4 comprising many tungsten carbide particles andtungsten-based metal carboboride particles precipitated when thecentrifugally cast layer 3 is formed, which are dispersed in anickel-based alloy matrix, and an inside particle-lack layer 5containing less tungsten carbide particles and metal carboborideparticles. The centrifugally cast layer 3 has a hollow portion 6 inside.The particle-lack layer 5 is removed from the centrifugally cast layer 3by machining, with the lining layer 4 having a predetermined thicknessremaining, thereby obtaining the molding machine cylinder 1 of thepresent invention.

[1] Molding Machine Cylinder

(A) Composition of Lining Layer

Because the lining layer 4 has a structure in which tungsten carbideparticles and tungsten-based metal carboboride particles are dispersedin a nickel-based alloy matrix, the composition of the entire lininglayer 4 differs from the matrix composition. In order that the lininglayer 4 exhibits excellent wear resistance and corrosion resistance withchipping suppressed during machining, the lining layer 4 preferably hasthe following composition (average composition including both matrix andhard particles).

(1) C: 1.5-4% by Mass

C is combined with W to form tungsten carbide particles andtungsten-based metal carboboride particles. When C is less than 1.5% bymass, tungsten carbide particles and metal carboboride particles areinsufficiently formed, failing to obtain sufficient wear resistance. Onthe other hand, when C exceeds 4% by mass, the lining layer 4 becomesbrittle, resulting in low machinability. The C content is preferably2-3.5% by mass.

(2) B: 0.5-3.5% by Mass

B is an element constituting metal carboboride particles, contributingto increasing wear resistance and stabilizing the thickness of theparticle-lack layer. When B is less than 0.5% by mass, this effect isnot obtained sufficiently. On the other hand, when B exceeds 3.5% bymass, the lining layer 4 becomes brittle, resulting in lowmachinability. The B content is preferably 1-2.5% by mass.

(3) W: 25-60% by Mass

W is combined not only with C to form tungsten carbide particles, butalso with B and C to form tungsten-based metal carboboride particles.When W is less than 25% by mass, tungsten carbide particles and metalcarboboride particles are insufficiently formed, failing to obtainsufficient wear resistance and to sufficiently stabilize the thicknessof the particle-lack layer. On the other hand, when W exceeds 60% bymass, the lining layer 4 becomes brittle, resulting in lowmachinability. The W content is preferably 35-50% by mass.

(4) Nickel: Balance

Ni is a main element constituting the matrix. The matrix containing 20%or more by mass of Ni exhibits excellent corrosion resistance. The Nicontent is preferably 25% or more by mass, more preferably 30% or moreby mass.

The lining layer 4 properly contains the following elements, dependingon the application and usage of the molding machine cylinder 1.

(5) Co: 1-15% by Mass

Like Ni, Co has a function of imparting corrosion resistance to thelining layer 4, and is dissolved in the matrix to improve the strength.When Co is less than 1% by mass, these effects are not obtainedsufficiently. On the other hand, when Co exceeds 15% by mass, theseeffects are saturated, economically disadvantageous. The Co content ismore preferably 2-10% by mass.

(6) Cr: 1-10% by Mass

Cr is mainly dissolved in the matrix to increase the strength, and formschromium-based metal carboboride particles. When Cr is less than 1% bymass, the strength-improving effect is unlikely obtained. On the otherhand, when Cr exceeds 10% by mass, excessive chromium-based metalcarboboride particles are formed, resulting in a brittle lining layer 4.The Cr content is more preferably 2-8% by mass. The amount ofchromium-based metal carboboride particles formed may be less than 1% byarea of the lining layer 4.

(7) Fe: 1-7.5% by Mass

Fe is dissolved in the matrix, contributing to improving adhesion to thecylinder. At least part of Fe comes from the steel cylinder fused bycentrifugal casting. When Fe is less than 1% by mass, sufficientadhesion to the cylinder is not obtained. On the other hand, more than7.5% by mass of Fe provides low corrosion resistance. The Fe content ismore preferably 1-7% by mass. The most preferable upper limit of the Fecontent is 6% by mass.

(8) Si: 0.1-3% by Mass

Si is dissolved in the matrix of the lining layer 4, increasinghardness, and thus improving wear resistance. When Si is less than 0.1%by mass, this effect is insufficient. On the other hand, when Si exceeds3% by mass, the lining layer 4 becomes brittle. The Si content is morepreferably 0.5-2.5% by mass.

(9) Mn: 0.1-2% by Mass

0.1% or more by mass of Mn exhibits a sufficient effect of removingforeign matter such as oxides, etc. However, when Mn exceeds 2% by mass,the corrosion resistance of the lining layer 4 is undesirablydeteriorated. The Mn content is more preferably 0.2-1% by mass.

(10) Cu: 0-5% by Mass

Cu is dissolved in the matrix of the lining layer 4 to improve thestrength. When it exceeds 5% by mass, the corrosion resistance of thelining layer 4 is deteriorated. The Cu content is more preferably 0-3%by mass.

(B) Composition of Lining Layer Matrix

After metal carboboride particles are precipitated, the matrix of thelining layer 4 preferably contains 50% or more by mass of nickel. Thematrix may contain Co, Cr, Si, C, B, Mn, W, Fe, Cu, etc., in addition toNi. The matrix of the lining layer 4 has a preferred compositioncomprising 50-75% by mass of Ni, 2-30% by mass of Co, 2-20% by mass ofCr, 0.2-5% by mass of Si, 0.05-1% by mass of C, 0.5-3% by mass of B,1-5% by mass of W, 0.2-5% by mass of Mn, 2-15% by mass of Fe, and 0-10%by mass of Cu, the balance being inevitable impurities. Fe is morepreferably 2-10% by mass.

(C) Hard Particles

(1) Tungsten Carbide Particles

The nickel-based alloy matrix of the lining layer 4 has a structure inwhich 20-50% by area of tungsten carbide particles and 1-10% by area oftungsten-based metal carboboride particles are dispersed. 1-10% by areaof metal carboboride particles can suppress the aggregation of tungstencarbide, making the particle-lack layer 5 in the centrifugally castlayer 3 thinner, and stably controlling the thickness of theparticle-lack layer 5. Accordingly, the centrifugally cast layer 3 needsnot be cut deep, resulting in a high material yield.

When tungsten carbide particles are less than 20% by area, the lininglayer 4 does not have sufficient wear resistance. On the other hand,when tungsten carbide particles exceed 50% by area, the lining layer 4becomes brittle, resulting in low machinability. Accordingly, the amountof tungsten carbide particles is 20-50% by area, preferably 25-40% byarea. The “% by area” of tungsten carbide particles is determined bymeasuring the area of tungsten carbide particles whose maximum diametersare 1 μm or more in a photograph of a cross section of the lining layer4 [photograph (magnification: 1000 times) mapping-analyzed by EPMA toidentify a matrix, tungsten carbide particles and metal carboborideparticles] by image analysis, and dividing it by the entire area of thecross section. The image analysis was conducted by image analysissoftware (Image-Pro Plus ver. 6.3 available from Media Cybernetics) on aphotograph of a cross section of the lining layer 4.

The tungsten carbide particles preferably have an average particle sizeof 1.5-15 μm. The average particle size is determined bynumber-averaging the maximum diameters of tungsten carbide particles.When the average particle size of tungsten carbide particles is lessthan 1.5 μm, the lining layer 4 has low wear resistance. On the otherhand, when the average particle size of tungsten carbide particlesexceeds 15 μm, tungsten carbide particles are likely detached andchipped when inner corners of the cylinder 2 are machined, resulting inreduced machinability. The average particle size of tungsten carbideparticles is more preferably 2-10 μm, further preferably 2-8 μm.

(2) Metal Carboboride Particles

Metal carboboride particles having more affinity than tungsten boride(WB) particles to the matrix have higher adhesion strength to thematrix, avoiding the deterioration of wear resistance by detaching. Themetal carboboride particles also suppress the aggregation andsegregation of tungsten carbide particles, contributing to providing thelining layer 4 with more uniform wear resistance. Further, bysuppressing the aggregation and segregation of tungsten carbideparticles, the thickness of the particle-lack layer 5 in thecentrifugally cast layer 3 can be stably controlled.

When the metal carboboride particles are less than 1% by area, tungstencarbide particles are aggregated in the lining layer 4, failing tostably control the thickness of the particle-lack layer. On the otherhand, when metal carboboride particles exceed 10% by area, the metalcarboboride particles likely become larger, resulting in more chippingduring machining, and thus lower machinability. Accordingly, the amountof metal carboboride particles is 1-10% by area, preferably 1-5% byarea, more preferably 1.5-4% by area. To suppress the aggregation oftungsten carbide particles, an area ratio of metal carboborideparticles/tungsten carbide particles is preferably 0.05-0.2, morepreferably 0.07-0.12. The “% by area” of metal carboboride particles isdetermined by measuring the area of metal carboboride particles whosemaximum diameters are 0.5 μm or more in a photograph of a cross sectionof the lining layer 4 by image analysis, and dividing it by the entirearea of the cross section. The image analysis was conducted by imageanalysis software (Image-Pro Plus ver. 6.3 available from MediaCybernetics) on a photograph of a cross section of the lining layer 4(photograph mapping-analyzed by EPMA to identify a matrix, tungstencarbide particles and metal carboboride particles).

The metal carboboride particles preferably comprise 65-85% by mass of W,0.5-6% by mass of B, 0.5-4% by mass of C, and 1-20% by mass of Ni. W isa main element constituting metal carboboride particles, formingcarboboride with C and B in the above ranges. W is more preferably70-80% by mass, B is more preferably 2-5% by mass, and C is morepreferably 1-3% by mass. The metal carboboride particles may containtrace amounts of metal components such as Fe, Cr, Co, etc., in additionto W and Ni.

When the metal carboboride particles contain 1% or more by mass of Ni,sufficient affinity for the matrix is obtained, with excellent adhesionto the matrix, resulting in less decrease in wear resistance bydetaching. When Ni exceeds 20% by mass, metal carboboride particles havereduced hardness, resulting in low wear resistance. The Ni content inmetal carboboride particles is more preferably 2-15% by mass.

The metal carboboride particles preferably have an average particle sizeof 0.5-5 μm. The average particle size is determined by number-averagingthe maximum diameters of metal carboboride particles. When the averageparticle size of metal carboboride particles is 0.5 μm or more, theaggregation of tungsten carbide particles can be suppressed, therebystabilizing the thickness of the particle-lack layer. However, when theaverage particle size of metal carboboride particles exceeds 5 μm, thelining layer 4 becomes brittle. The average particle size of metalcarboboride particles is more preferably 1-3 μm. The average particlesize of metal carboboride particles is preferably smaller than that oftungsten carbide particles. Specifically, an average particle size ratioof metal carboboride particles to tungsten carbide particles ispreferably 0.2-0.5.

[2] Production Method of Cylinder for Molding Machine

(A) Raw Material Powder

(1) Alloy Powder

The alloy powder is made of a Ni-based alloy containing at least 1-5% bymass of B. B lowers the melting point of the alloy powder to increasethe fluidity of an alloy melt, and forms metal carboboride particles toimprove the wear resistance and stabilize the thickness of theparticle-lack layer 5. When B is less than 1% by mass, these effects arenot obtained sufficiently. On the other hand, when B exceeds 5% by mass,the lining layer 4 becomes brittle. The B content is preferably 2-4% bymass. The Ni content in the Ni-based alloy is preferably 50% or more bymass. The alloy powder preferably contains 0.01-1% by mass of C, 2-20%by mass of Cr, 0.2-5% by mass of Si, 0.2-5% by mass of Mn, and 2-30% bymass of Co. The alloy powder may further contain 0-1% by mass of Fe, and0-5% by mass of Cu.

The average particle size of the alloy powder is preferably 20-300 μm.When the average particle size of the alloy powder is less than 20 μm,the alloy powder has a large specific surface area, likely sufferingsurface oxidation during production and heating. On the other hand, whenthe average particle size of the alloy powder exceeds 300 μm, thetungsten carbide powder and the alloy powder exhibit large fluiditydifference due to their particle size difference, so that both powdersmay be separated when the cylinder is rotated. The average particle sizeof the alloy powder is more preferably 50-200 μm. The average particlesize was measured by a laser diffraction particle size analyzer(Microtrac).

(2) Tungsten Carbide Powder

The tungsten carbide powder preferably has an average particle size of1.5-15 μm. When the average particle size of tungsten carbide powderexceeds 15 μm, tungsten carbide particles contained in the lining layer4 have too large particle sizes, likely detached during machining. Onthe other hand, when the average particle size of tungsten carbidepowder is less than 1.5 μm, the wear resistance of the lining layer 4 isnot sufficiently improved. The average particle size of tungsten carbidepowder is more preferably 7-15 μm, most preferably 7-12 μm. The averageparticle size was measured by a laser diffraction particle size analyzer(Microtrac). Also, fine tungsten carbide powder is preferably containedin a proper amount, because part of their surfaces are easily meltedduring heating (in the first heating step described below) beforecentrifugal casting, contributing to the precipitation of metalcarboboride in centrifugal casting. The tungsten carbide powderpreferably has a particle size distribution that particle sizes of 6 μmor less are 0.2-20% by weight.

(3) Formulation

A raw material for the lining layer comprises 40-70 parts by mass of thealloy powder and 60-30 parts by mass of the tungsten carbide powder.When the alloy powder is more than 70 parts by mass (the tungstencarbide powder is less than 30 parts by mass), the lining layer 4 doesnot have sufficient wear resistance. On the other hand, when the alloypowder is less than 40 parts by mass (the tungsten carbide powder ismore than 60 parts by mass), the lining layer 4 has too high hardness.More preferably, the alloy powder is 40-60 parts by mass, and thetungsten carbide powder is 60-40 parts by mass.

(4) Melting

A mixed powder of the alloy powder and the tungsten carbide powder (rawmaterial for the lining layer) is charged into a cylinder 2 made ofsteel such as SCM440, etc., and melted while rotating the cylinder 2 at5-30 rpm. The heating step of the raw material for the lining layercomprises a first step of heating at higher than 1140° C. and lower than1200° C., and a second step of heating at 1080-1140° C. after the firstheating step.

(a) First Heating Step

By heating the raw material for the lining layer at a relatively hightemperature of higher than 1140° C. and lower than 1200° C., part ofsurfaces of tungsten carbide particles are sufficiently melted in analloy melt. A heating temperature of 1140° C. or lower does notsufficiently melt tungsten carbide, while a heating temperature of 1200°C. or higher erodes the steel cylinder too much, resulting in too highconcentration of iron in the lining layer 4. The heating temperature inthe first heating step is preferably 1150-1190° C. The heating time inthe first heating step may be about 10-60 minutes. Because the heatingtemperature is sufficiently high in the first heating step, alloy oxidesinevitably generated are melted and segregated on the inside duringcentrifugal casting, so that they do not remain in the lining layer 4.

(b) Second Heating Step

With as relatively low a heating temperature as 1080-1140° C., part ofsurfaces of tungsten carbide particles are further melted in the alloymelt while suppressing the erosion of the cylinder 2, causing sufficientreactions of W, B and C in the alloy melt to precipitate tungsten-basedmetal carboboride. The heating time in the second heating step is asrelatively long as 60-120 minutes, to sufficiently precipitate metalcarboboride. Because the second heating step is conducted for arelatively long period of time, the upper limit of the heatingtemperature should be 1140° C. or lower to suppress the erosion of thecylinder 2. The upper limit of the heating temperature is preferably1135° C. When the heating temperature is lower than 1080° C., the alloymelt has low fluidity, resulting in a reduced stirring effect byrotation, failing to sufficiently obtain metal carboboride particles.The lower limit of the heating temperature is preferably 1100° C.

(c) Rotation Speed of Cylinder

With the cylinder 2 rotated at as relatively low a speed as 5-30 rpm inthe first and second heating steps, the melting of tungsten carbide andthe precipitation of metal carboboride are accelerated by stirring thealloy melt, while suppressing the erosion of an inner surface of thecylinder 2, and the temperature of the alloy melt is made uniform,resulting in uniformly precipitated metal carboboride particles. Whenthe number of rotation of the cylinder 2 is less than 5 rpm, a stirringfunction is insufficient, failing to uniformly precipitate a sufficientamount of metal carboboride particles. On the other hand, the number ofrotation of the cylinder 2 exceeding 30 rpm provides an excessivestirring function, likely making metal carboboride particles too large.The preferred number of rotation of the cylinder 2 is 5-15 rpm.

(5) Centrifugal Casting

After tungsten-based metal carboboride particles are precipitated whilemelting part of surfaces of tungsten carbide particles, the cylinder 2is rotated at a high speed exceeding 1000 rpm (for example, 1200-2500rpm) to carry out centrifugal casting. Because heating is not conductedduring the centrifugal casting, the alloy melt is gradually cooled, sothat metal carboboride particles are further precipitated. Thus formedis a centrifugally cast layer 3 composed of an outside lining layer 4having many tungsten carbide particles and metal carboboride particlesdispersed, and an inside particle-lack layer 5 containing less tungstencarbide particles and metal carboboride particles.

(6) Removal of Particle-Lack Layer

Because the particle-lack layer 5 has a stable thickness in thecentrifugally cast layer 3 formed by the method of the presentinvention, the centrifugally cast layer 3 may be removed in smallthickness by machining. If the particle-lack layer 5 had uneventhickness, removal would have to be conducted exceeding theparticle-lack layer 5 to a relatively thick part of the lining layer 4for safety margin, failing to obtain a lining layer 4 having sufficientthickness. Thus, the molding machine cylinder 1 comprising a lininglayer 4 containing 20-50% by area of tungsten carbide particles and1-10% by area of tungsten-based metal carboboride particles dispersed ina nickel-based alloy matrix, is obtained.

The present invention will be explained in more detail with Examplesbelow, without intention of restricting the present invention thereto.

Examples 1-3, Reference Examples 1 and 2, and Comparative Examples 1-3

Each alloy powder having a composition shown in Table 1 was produced bya gas atomizing method, and classified by a sieve to have an averageparticle size shown in Table 2. Each alloy powder was dry-mixed withtungsten carbide powder having purity of 99% or more and an averageparticle size shown in Table 2. Table 2 shows the amounts of alloypowder and tungsten carbide powder in each raw material for the lininglayer.

TABLE 1 Composition (% by mass) of Alloy Powder No. B C Cr Fe Si Mn CoCu Ni Example 1 3.1 0.05 8.3 — 3.6 1.1 8.1 — Balance Example 2 2.6 0.1212.5 0.1 3.6 1.1 18.5 2.5 Balance Example 3 3.1 0.05 8.3 — 3.6 1.1 8.1 —Balance Ref. Ex. 1 3.8 0.08 15.8 4.9 3.6 1.1 35.0 5.2 Balance Ref. Ex. 23.1 0.05 8.3 — 3.6 1.1 8.1 — Balance Com. Ex. 1 3.1 0.05 8.3 — 3.6 1.18.1 — Balance Com. Ex. 2 3.1 0.05 8.3 — 3.6 1.1 8.1 — Balance Com. Ex. 33.1 0.05 8.3 — 3.6 1.1 8.1 — Balance

TABLE 2 Tungsten Alloy Powder Carbide Powder Average Amount AverageAmount Particle Size (parts by Particle Size (parts by No. (μm) mass)(μm) mass) Example 1 110 60 5.0 40 Example 2 46 70 13.9 30 Example 3 11760 8.8 40 Ref. Ex. 1 60 75 9.0 25 Ref. Ex. 2 110 60 5.0 40 Com. Ex. 1110 60 5.0 40 Com. Ex. 2 110 85 5.0 15 Com. Ex. 3 110 60 200 40

Each raw material for the lining layer was charged in an amount offorming as thick a centrifugally cast layer as 4 mm into a cylinder of250 mm in outer diameter, 94 mm in inner diameter and 2500 mm in lengthmade of machine-structural alloy steel (SCM440), and steel lids werewelded to both end openings of the cylinder for sealing. This cylinderwas put in a furnace having a rotation mechanism, to carry out the firstand second heating steps while rotating the cylinder under theconditions shown in Table 3.

TABLE 3 First Heating Step Second Heating Step Heating Heating Number ofTemper- Heating Temper- Heating Rotation ature Time ature Time No. (rpm)(° C.) (minute) (° C.) (minute) Example 1 6 1160 30 1120 60 Example 2 201180 30 1130 90 Example 3 10 1180 30 1140 90 Ref. Ex. 1 20 1180 30 113060 Ref. Ex. 2 6 1180 90 — — Com. Ex. 1 0 1150 30 — — Com. Ex. 2 10 116030 1120 60 Com. Ex. 3 60 1160 30 1120 60

After the second heating step, each cylinder was taken out of thefurnace, and placed on a centrifugal casting apparatus. A centrifugallycast layer having a thickness of 4 mm was formed by a centrifugalcasting method by rotating the cylinder at a gravitational accelerationof 80 G (1230 rpm) on an inner surface of the cylinder, until thetemperature was lowered to 700° C. After cooling to room temperature,two disc-shaped samples as thick as 20 mm were cut out of the cylinderat each center position separated 100 mm from each end.

Composition/structure-observing samples of about 20 mm×20 mm×20 mm werecut out of each disc-shaped sample from an inner surface of its circularhole circumferentially every 90°, and mirror-polished. The thickness ofa particle-lack layer in a centrifugally cast layer of each sample wasmeasured by a scanning electron microscope, to determine its minimum andmaximum. Table 8 shows a thickness range of the particle-lack layer.FIG. 2 is a scanning electron photomicrograph showing the centrifugallycast layer 3 of Example 1, and FIG. 3 is a photograph of the lininglayer 4 mapping-analyzed by EPMA to identify a matrix, tungsten carbideparticles and metal carboboride particles. In FIG. 3, a dark grayportion is a nickel-based alloy matrix, thin gray particles are tungstencarbide (WC) particles, and white particles are metal carboboride (WBC)particles. FIG. 3 shows that WC particles and WBC particles wereuniformly dispersed in the nickel-based alloy matrix of the lining layer4.

The particle-lack layer 5 was removed from eachcomposition/structure-observing sample to analyze components in thelining layer 4. Table 4 shows the composition of the lining layer 4(average composition including all of an alloy matrix, tungsten carbideand metal carboboride).

TABLE 4 Composition (% by mass) of Lining Layer No. C B W Cr Fe Si Mn CoCu Ni Example 1 2.8 1.5 42.0 3.6 4.1 1.1 0.5 4.8 — Balance Example 2 2.61.6 36.3 8.4 6.6 1.9 0.5 10.8 2.7 Balance Example 3 3.2 1.2 52.7 3.1 7.20.9 0.4 4.1 — Balance Ref. Ex. 1 2.6 1.6 36.3 8.4 8.3 1.9 0.5 21.6 2.7Balance Ref. Ex. 2 3.2 1.2 55.7 3.1 12.1 0.9 0.4 4.1 — Balance Com. Ex.1 4.1 1.3 55.4 2.6 0.5 1.3 0.3 3.9 — Balance Com. Ex. 2 1.4 1.8 23.0 4.65.8 1.5 0.9 7.3 — Balance Com. Ex. 3 2.7 1.5 41.9 3.9 3.6 0.9 0.6 3.5 —Balance

The metal composition of a matrix in eachcomposition/structure-observing sample was analyzed by EDX. Table 5shows the composition of detectable metal elements in the matrix. Table6 shows the area percentages and average particle sizes of tungstencarbide particles and metal carboboride particles, and Table 7 shows thecomposition of metal carboboride particles measured by EPMA.

TABLE 5 Composition (% by mass) of Matrix No. Ni W Cr Fe Mn Co CuExample 1 71.3 2.1 5.9 6.7 0.8 9.5 — Example 2 51.7 4.9 10.8 8.9 0.815.3 4.2 Example 3 68.9 1.7 4.8 14.3 0.5 5.8 — Ref. Ex. 1 24.5 4.9 13.811.1 0.8 36.1 4.2 Ref. Ex. 2 55.6 1.7 4.8 27.2 0.5 5.8 — Com. Ex. 1 70.11.9 6.3 6.5 0.7 10.4 — Com. Ex. 2 71.6 0.9 7.1 6.9 1.4 11.6 — Com. Ex. 368.9 1.6 6.1 6.1 0.8 9.8 —

TABLE 6 Tungsten Carbide Metal Carboboride Particles Particles AverageAverage % Particle Size % Particle Size No. by area (μm) by area (μm)Example 1 35.2 4.2 6.5 2.2 Example 2 26.7 6.4 2.3 1.1 Example 3 33.8 3.62.6 1.6 Ref. Ex. 1 26.1 18.4 16.9 7.5 Ref. Ex. 2 51.9 8.6 3.2 0.7 Com.Ex. 1 38.8 21.0 0.1 0.2 Com. Ex. 2 17.4 4.2 2.4 2.2 Com. Ex. 3 38.6190.0 25.7 12.3

TABLE 7 Composition (% by mass) of Metal Carboboride Particles No. C B WNi Example 1 1.8 3.0 76.4 9.9 Example 2 1.6 3.2 71.6 5.2 Example 3 1.82.9 75.2 7.8 Ref. Ex. 1 1.6 3.2 71.6 2.6 Ref. Ex. 2 1.8 2.9 75.2 7.8Com. Ex. 1 0.3 3.2 70.4 8.1 Com. Ex. 2 1.7 2.8 55.2 27.1 Com. Ex. 3 1.93.5 76.2 13.5

As shown in FIG. 4, a lining layer 13 of a wear test piece of 10 mm indiameter (comprising a cylinder substrate 12 and a lining layer 13) cutout of each disc-shaped sample was pressed at pressure P of 90 N to aSiC sandpaper (#400) 11 on a table 10 rotating at 150 rpm for apredetermined period of time, for an abrasive wear test. Wear wasdetermined from the weight of the test piece before and after theabrasive wear test. The results are shown in Table 8.

TABLE 8 Thickness (mm) Cen- Particle- trifugally Lack Wear Corrosion No.Cast Layer Layer (mg) Machinability Resistance Example 1 4 0.7-0.9 2.5Good Good Example 2 4 0.9-1.1 3.4 Good Good Example 3 4 1.2-1.5 2.0 GoodGood Ref. Ex. 1 4 1.5-1.6 3.6 Good Fair Ref. Ex. 2 4 1.6-1.9 2.2 GoodPoor Com. Ex. 1 4 2.2-2.9 2.3 Poor Good Com. Ex. 2 4 1.4-1.9 12.5 GoodGood Com. Ex. 3 4 1.1-1.5 2.7 Poor Good

The particle-lack layer 5 was removed by grinding from the centrifugallycast layer 3 of each cylinder after the disc-shaped sample was cut out.An inner-surface corner portion of each cylinder was cut by turning witha CBN tool, to evaluate machinability with the detaching and chipping oftungsten carbide particles and metal carboboride particles from thelining layer 4, by the following standard. The results are shown inTable 8.

Good: Detaching and chipping did not occur.

Poor: Detaching or chipping occurred.

A corrosion resistance-evaluating sample of 1.5 mm in thickness, 4.0 mmin width and 10 mm in length was cut out of the lining layer 4. Eachsample was immersed in an 18-% hydrochloric acid solution at 50° C. for24 hours, to evaluate corrosion resistance with a weight reduction ratioby immersion by the following standard. The results are shown in Table8.

Good: The weight reduction ratio was less than 7%.

Fair: The weight reduction ratio was 7% or more and less than 15%.

Poor: The weight reduction ratio was 15% or more.

When each centrifugally cast layer 3 of Examples 1-3 was cut to thedepth of 2 mm, the particle-lack layer 5 was completely removed, so thatthe lining layer 4 was exposed to the entire inner surface of thecylinder. Thereafter, the outer periphery and ends, etc. of the cylinder2 were machined to produce a molding machine cylinder 1. When injectionmolding was conducted using the molding machine cylinder 1 of Example 1,it was confirmed that the lining layer 4 had good wear resistance andcorrosion resistance.

On the other hand, when the centrifugally cast layer 3 of ComparativeExample 1 was cut to the depth of 2 mm, a too thick particle-lack layer5 was not completely removed, failing to have a lining layer 4 on theentire inner surface of the cylinder.

When each centrifugally cast layer of Reference Examples 1 and 2 andComparative Example 2 was cut to the depth of 2 mm, the particle-lacklayer 5 was completely removed to expose a lining layer 4. A moldingmachine cylinder 1 was then produced by machining. However, wheninjection molding was conducted using the molding machine cylinder 1 ofReference Example 1, the lining layer 4 was slightly poor in corrosionresistance because the matrix had a relatively small Ni content. Wheninjection molding was conducted using the molding machine cylinder 1 ofReference Example 2, the lining layer 4 did not exhibit sufficientcorrosion resistance because the lining layer had a large Fe content.When injection molding was conducted using the molding machine cylinder1 of Comparative Example 2, the lining layer 4 was prematurely wornbecause of too small an area ratio of tungsten carbide particles,failing to exhibit sufficient wear resistance.

As is clear from Table 8, the thickness differences between the maximumand minimum (unevenness) of the particle-lack layers 5 in Examples 1-3were within a range of 0.1-0.3 mm. On the other hand, the thicknessunevenness of the particle-lack layers 5 in Comparative Examples 1-3 wasas large as 0.4-0.7 mm. This indicates that in Examples 1-3, thethickness of the particle-lack layer 5 is stably controlled.

DESCRIPTION OF REFERENCE NUMERALS

-   -   1: Molding machine cylinder    -   2: Cylinder    -   3: Centrifugally cast layer    -   4: Lining layer    -   5: Particle-lack layer    -   6: Hollow portion    -   11: Sandpaper    -   12: Substrate of test piece    -   13: Lining layer of test piece

What is claimed is:
 1. A molding machine cylinder comprising a lininglayer formed on an inner surface of a steel cylinder by a centrifugalcasting method; said lining layer having a structure comprising 20-50%by area of tungsten carbide particles and 1-10% by area oftungsten-based metal carboboride particles in a nickel-based alloymatrix; and said lining layer containing 1-7.5% by mass of Fe whereinthe % by area is based on a cross section of the lining layer, whereinsaid metal carboboride particles contain 0.5-4% by mass of C, 0.5-6% bymass of B, 65-85% by mass of W, and 1-20% by mass of Ni.
 2. The moldingmachine cylinder according to claim 1, wherein said metal carboborideparticles have an average particle size of 0.5-5 μm.
 3. The moldingmachine cylinder according to claim 1, wherein said tungsten carbideparticles have an average particle size of 1.5-15 μm.
 4. The moldingmachine cylinder according to claim 1, wherein said lining layercomprises 1.5-4% by mass of C, 0.5-3.5% by mass of B, 25-60% by mass ofW, 1-10% by mass of Cr, 1-15% by mass of Co, 0.1-3% by mass of Si,0.1-2% by mass of Mn, and 0-5% by mass of Cu, the balance being nickeland inevitable impurities.
 5. The molding machine cylinder according toclaim 4, wherein a matrix of said lining layer comprises 0.05-1% by massof C, 0.5-3% by mass of B, 1-5% by mass of W, 2-20% by mass of Cr, 2-30%by mass of Co, 0.2-5% by mass of Si, 0.2-5% by mass of Mn, 2-15% by massof Fe, and 0-10% by mass of Cu, the balance being nickel and inevitableimpurities.